Compact creel

ABSTRACT

A highly mobile, compact creel ( 20 ) that utilizes frames ( 22 ) for holding yarn packages ( 30 ) (or bobbins) for feeding yarn ( 33 ) to a tufting machine ( 58 ). Each frame ( 22 ) includes holders ( 60 ) affixed to the frame ( 22 ) for holding yarn packages ( 30 ) facing front ( 24 ) and back ( 26 ), a header ( 32 ) attachable to the frame ( 22 ) for directing yarn ( 33 ) from the yarn packages ( 30 ) to the tufting machine ( 58 ), and anti-static flexible tubing ( 50 ) for leading yarn ( 33 ) from the holders ( 60 ) to the header ( 32 ). The header ( 32 ) provides for aligning all the yarn ends in the same plane to join them to ends already threaded into the tufting machine ( 58 ). An optional frame overlay upright ( 81 ) having a ring ( 78 ) affixed thereto and strands ( 84 ) threaded through the ring ( 78 ) prevents yarn ( 33 A) from upper yarn packages ( 30 A) from falling onto tubes ( 60 B) holding lower yarn packages ( 30 B) causing yarn entanglement

RELATED APPLICATIONS

This application claims priority to U.S. Patent Application No.60/107,494 filed Nov. 6, 1998, entitled, “Compressed Portable TuftingCreel,” U.S. Patent Application No. 60/107,495 filed Nov. 6, 1998,entitled, “Alignment Header for Burning-In Process,” and U.S. PatentApplication No. 60/134,589 filed May 17, 1999, entitled, “CompactCreel,” all which are incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates in general to the field of carpet production, andin particular, to carpet yarn creels.

BACKGROUND OF THE INVENTION

Carpet tufting machines are relatively compact devices. However,substantial space within a carpet production facility is required forthe entire tufting process. In addition to the space occupied by atufting machine (i.e. the tufter) itself, there must be roll-up oradditional processing equipment, or both, positioned downstream from thetufter.

Substantial additional space is required to supply yarn to the tufter.Yarn is typically supplied directly to the tufter by one of two methods.It may come from a “creel,” which is a rack holding large bobbins orpackages of yarn that spool off of the bobbins and into the tufter.Conventional creels occupy substantial floor space “upstream” from thetufter because of the size of the packages or bobbins of yarn and thespace needed to hold them so that the many separate strands of yarn canbe pulled off the bobbins and fed into the tufting machine. The floorspace required by a standard warper and creel is on the order of 2,000square feet.

Alternatively, yarn can be fed to the tufting machine from a “beam,” alarge horizontal mandrel onto which multiple strands of yarn of theneeded colors are wound in advance. The yarn strands are then unwoundsimultaneously from the beam into the tufter. While beams typicallyrequire substantially less space immediately in front of the tufter thanconventional creels, substantial space is needed, and significant workis required to prepare the beam, because in order to position yarn on abeam, bobbins or yarn packages must be positioned on creels to “feed”the beam, much as the yarn packages would be positioned to feed a tufterdirectly.

A significant challenge to carpet manufacturers is to reduce the amountof yarn waste occurring in the manufacturing of carpet. Wasted yarn canoccur in several stages during the manufacturing process. For example,there can be yarn waste due to tufting beam waste, production beam wasteand/or warping beam waste. A cause of waste is the inability toeffectively determine the amount of yarn that is needed for a particularpiece of carpet. As yarn is fed into a tufting machine it may berealized that yarn length for one color in a pattern is too short whileyarn length for another color in the pattern is too long, resulting inwasted yarn. Large bobbins of yarn or beams of yarn compound the problemdue to the sheer size of the yarn contained. A compact creel withsmaller yarn packages reduces waste in the manufacturing process.Another significant problem is carpet overrun overage.

Therefore, a need exists for a compact creel that occupies less space onthe manufacturing floor and reduces yarn waste in the manufacturingprocess, while enabling the same quantities of carpet production as thatproduced from a conventional creel.

SUMMARY OF THE INVENTION

This invention is a highly mobile, compact creel that utilizes framesfor holding yarn packages (or bobbins), where the packages may be in theform supplied by the yarn supplier (typical sizes are initially about 6inches or about 10-11 inches in diameter). Each frame can hold yarnpackages facing front and back. Each creel frame can hold, for instance,about 416 yarn packages, for a total of approximately 832 yarn packages,so that the two sides of the frames together hold sufficient yarn endsfor a typical carpet tufting machine. Other numbers of packages can alsobe accommodated, and multiple frames can be used to feed a singletufting machine.

A header having adjustable bars and slots for the yarn mates and affixesto the frame. This header provides for aligning all of the yarn ends inthe same plane in order to join them to ends already threaded into thetufting machine.

In operation, yarn spools off of the end of the yarn package, through aneyelet (or yarn eye), through a rigid tube affixed to the frame (andinside the hollow yarn package), and through a flexible tube leading tothe top of the frame, and into the header. The flexible tube typicallypasses through the rigid tube on which the package rests and a yarn eyeat the end of the rigid tube can be formed on the end of the flexibletube. The floor space required for two 16 foot frames of the compactcreel of this invention is on the order of 160 square feet.

A yarn reclamation procedure of this invention strips the yarn packageswithout unloading the yarn packages from the creel. The ends of the yarntie from head to tail. The portable creel is placed in front of abackwinder head, and skinner yarn pieces wind onto one package or a fewpackages.

Objects of this invention include:

To provide a compact creel that reduces yarn waste in the tufting,production and warping processes.

To provide an alternative use for warping beam yarn, other than overruncarpet or beam waste.

To provide a compact creel that increases the quality of the finishedproduct by reducing slack ends.

To provide yarn inventory reduction and decreased amounts of materialhandling.

To provide a compact creel that requires less floor space.

To provide an efficient reclamation procedure.

To provide a compact creel that reduces the labor required in thewarping process.

To provide simplified scheduling and increased plant through-put time.

To provide all the same features for sample production and carpetdevelopment.

As the following description and accompanying drawings make clear, theseand other objects are achieved by this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of both sides of a compact creel of thisinvention including a frame, a header, yarn packages on hollow supportsand flexible tubing.

FIG. 2 is an exploded perspective view of a portion of the compact creelof FIG. 1, including a hollow support for a yarn package shown in brokenlines and a support, a flexible yarn tube and a portion of the header.

FIG. 3 is a side elevation view of a front and rear portion of the creelof FIG. 1.

FIG. 4 is a side view, partially in section of the end of a packagesupport tube and flexible tubing.

FIG. 5 is an end view, partially in section of the header.

FIG. 6 is a side elevation view of two of the creels of FIG. 1 showingthe path yarn takes to enter a tufting machine with yarn from one creeltraveling over the other creel.

FIG. 7 is a side elevation view of two yarn packages illustrating theproblem of yarn falling from one yarn package to another yarn packageand becoming entangled therein.

FIG. 8 is a side elevation view of two yarn packages and an air shunt inthe flexible tubing for blowing air through the flexible tubing and aring having lines for capturing any slack yarn to avoid the problem ofthe yarn becoming entangled as shown in FIG. 7.

FIG. 9 is a perspective view of the ring, threaded shank and lineaffixed to the overlay upright taken at oval “9” in FIG. 8.

FIG. 10 is a perspective view of the creel having the overlay upright,ring, shank and lines of FIG. 9 extending across the front and rearportions of the frame.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of a compact creel 20 of this invention.The compact creel 20 includes a frame 22 having a front portion 24 and arear portion 26, multiple hollow supports 28 attached to the frame 22for holding yarn packages 30, and an attachable header 32. Preferably,the frame 22 can hold about 832 yarn packages 30 with approximately 416yarn packages 30 on each of the front 24 and rear 26 portions of asixteen foot frame 22. Generally, the yarn packages 30 have a diameterof about seven inches and are about twelve inches long. Preferably, theoverall footprint of the compact creel 20 is on the order of 160 squarefeet or less. A variety of yarn packages 30 can be used with the compactcreel 20 including yarn packages 30 containing yarn 33, that is forinstance, tightly twisted, loosely twisted and air entangled. Casters34, 36, 38, 40, 42 and 44 placed on the bottom of the frame 22 providefor ease of movement of the compact creel 20.

As illustrated in FIG. 1, the yarn packages 30 of the creel 20 arearranged in compact staggered rows. The hollow supports 28 holding theyarn packages 30 are closely spaced, for instance about one inch apart,so that side-to-side and above-and-below positions of yarn packages 30are close. This configuration is an improvement over the existingarrangements that requires large bobbins of yarn occupying substantialspace before feeding into a tufting machine, and a labor intensive setup process. The compactness of the yarn packages 30, the large quantityof yarn packages 30 fitting on a creel 20 and reductions in set-up andlabor costs provide for a more efficient system for delivering yarn to atufting machine.

Preferably, the front portion 24 and the rear portion 26 of the frame 22define a passageway 46. Flexible anti-static tubing 50 affixes to theheader 32 at one end 52 of the flexible tubing 50 and travels throughthe passageway 46 with the other end 54 (not shown) of the flexibletubing 50 positioned through the hollow support 28. Yam 33 feeds throughthe flexible tubing 50 to the header 32, and through the slots 56 in theheader to the tufting machine (represented by dash line 58). Thearrangement of the header 32 and slots 56 ensures that yarns feedinginto the tufting machine 58 lie in the same plane.

FIG. 2 shows a perspective view of the hollow support 28. The hollowsupport 28 includes a tube 60, a retainer spring clip 62, and aconnector 64. The hollow support 28 can be configured, for instance, asa length of round or square pipe or metal tube. Preferably, the tube 60is welded to the frame 22, and the connector 64 having the retainerspring clip 62 attaches to the tube 60. The connector 64 can attach tothe tube by a variety of methods including, for instance, screwing,welding, and gluing. The tube 60 is hollow, allowing the flexible tubing50 to be positioned therein. The yarn package 30 is removably placed onthe hollow support 28. An eyelet 66 formed by heat flaring the end 54 ofthe flexible tubing 50.

During setup of the creel 20, an end of a strand of yarn 33 is unwrappedfrom the yarn package 30. The yarn 33 is blown through the flexibletubing 50 up to the header 32. As yarn 33 spins off the yarn package 50,the eyelet 66 serves to allow continuous feeding from the yarn package30 through the flexible tubing 50, aids the threading process and helpsavoid wear as the yarn 33 is pulled through. Alternatively, a ceramic orceramic-coated yarn eye may be attached to the end of the tube 60. Asshown in FIG. 2, the flexible tubing 50 snakes behind the frame 22 andtraverses up to the header 32. The other end 52 of the flexible tubing50 that affixes to the header 32 can also be heat flared ensuring theflexible tubing 50 remains in place on the header 32 by the heat flaredend 68. Preferably, yarn 33 removal from the yarn packages 30 onto thetufting machine 58 is relatively slow, with little wear on the heatflared end of the flexible tubing 50.

FIG. 3 is a side elevation view of the front 24 and rear 26 portion ofthe frame 22 of the creel 20 of FIG. 1. As shown in FIG. 3, the flexibletubing 50 travels from the hollow support 28 up the passageway 46 of theframe 22 to the header 32. As shown, both portions 24, 26 of the frame22 contain a plurality of yarn packages 30. Yarn 33 inside the flexibletubing 50 travels through the passageway 46 to the header 32. Yarn 33exiting the header 32 aligns to enter the tufting machine 58.

FIG. 4 is an enlarged side elevation view of the end tube 60. Tube 60contains the flexible tubing 50 with an eyelet 66 at the end 54 of theflexible tubing. The eyelet 66 serves to hold the flexible tubing 50 inplace within the tube 60.

FIG. 5 is an enlarged side view of the header 32. The header 32 includesa first plate 70 and a second plate 72. The flexible tubing 50 threadsthrough the first plate 70. The heat flared end 68 of the flexible tube50 serves to keep the flexible tubing 50 from coming out of the firstplate 72. The heat flared end 68 of the flexible tubing 50 abuts thesecond plate 72. The second plate 72 attaches to the first plate 70 byany connecting methods such as, for example, bolts 74.

FIG. 6 is a side elevation view of two creels 20 and 21 placed one infront of the other. Because of the portable nature of the compact creel20, more than one compact creel 20, 21 can be used at the same time witha tufting machine 58. After one compact creel 20 is set up and connectedto the tufting machine 58, the second compact creel 21 can be placedinto position and attached to the tufting machine 58. The first creel 20is positioned closest to the tufting machine 58. The second creel 21placed behind the first creel 20 has all the elements of the first creel20 with an additional feature. The second creel 21 includes a yarn guide74 for directing the yarn 33 exiting the header 32 over the first creel20 and into the tufting machine 58. The yarn guide 74 creates an angledpath for the yarn 33 to traverse, as illustrated by directional arrowA-A to insure that the yarn 30 does not travel a path that wouldinterfere with the operation of the first creel 20. The yarn 33 exitingthe first creel 20 travels path B-B which is a separate path from pathA-A.

In an alternative embodiment, the yarn guide 74 includes a yarn slidethat is placed across the top of the compact creel 21. The yarn guidecan include a bar affixed to and positioned above an upper portion ofthe frame 22. So that yarn coming from the header 32 of the secondcompact creel 21 into the tufting machine 58 is not damaged or brokenwhen the first compact creel 20 slides into position, the yarn slideacts as a “roof” that allows the yarn to slide along an upper portion ofthe yarn slide as the first creel 20 is placed in proper position.

FIG. 7 is a schematic side elevation view of two yarn packages 30A and30B illustrating how yarn 33A falls from one yarn package 30A to anotheryarn package 30B and becomes entangled. The hollow support 28 thatsupports the yarn packages 30 (including 30A and 30B) allows the yarn tospool off at a variety of speeds including high speeds of about 800 rpm.Yarn packages 30 having different tensions of yarn 33 (including 33A and33B) on the yarn packages 30 such as loosely twisted or tightly twistedyarn 33 can spool off the yarn package 30 at different rates. Yarnpackages 30 containing different types of yarn 33 placed above eachother can cause the yarn from one package to become entangled withanother package. FIG. 7 shows this situation where the yarn 33A from theupper yarn package 30A, mounted on tube 60A, has fallen onto the tube60B of the lower yarn package 30B. This problem causes the yarn 33A tojam, requiring stopping the operation of the creel to untangle the yarnpackages 30A and 30B which can negatively affect productivity.

FIG. 8 shows a method for addressing the yarn entanglement problemincluding a ring having a line for capturing any slack yarn to avoid theproblem of the yarn becoming entangled as shown in FIG. 7. The ring 78having a threaded shank 80 (shown in FIG. 9) received in an overlayupright 81 and held in place by a nut 82. A line or strand 84, such as,for instance, fishing wire or monofilament line, loops through the ring78 and extends across the overlay upright 81 and attaches at theopposite end of the overlay upright 81 (shown in FIG. 10). The frontportion 24 and rear portion 26 of the overlay upright 81 can containsuch strands 84. The placement of the ring 78 and strand 84 avoids theproblem of yarn 33A entanglement by supporting any loose yarn on thestrand as shown at 86. Further, even if yarn 33A is very loose and fallsdown to the lower yarn package 30B, the yarn follows the likely pathshown at 87 and does not become entangled in the tube 60B of the loweryarn package 30B.

FIG. 8 also illustrates use of a shunt for blowing air through theflexible tubing 50. Shunt 90 attaches to the flexible tubing 50providing an alternative location for air entry to blow the yarn 33through the flexible tubing 50. In another alternative embodiment,multiple shunts can be fed by a single manifold so that air cansimultaneously be blow through tubes 50.

FIG. 9 is a perspective view of the ring 78, shank 80 and strand 84taken at oval “9” in FIG. 8. The wire 84 extends across the front andrear portions 22, 24 of the frame 22 such that yarn 33A from an upperyarn package 30A does not become entangled with yarn 33B from a loweryarn package 30B.

FIG. 10 is a perspective view of the front portion 24 of a compact creel85 having the strands 84 of FIG. 9 extending across overlay uprights 81.The overlay uprights 81 contain a series of rings 78 for attachingstrands 84 between each horizontal row of yarn packages 30 to preventyarn 33A from an upper yarn package 30A from inadvertently wrappingaround a tube 60B of a lower yarn package 30B entangling the yarn 33A.

Yarn reclamation can occur by stripping the yarn 33 from the yarnpackages 30. without unloading the yarn packages 30 from the creel 20,21 and 85. The ends of the yarn 33 in adjacent packages 30 are tied fromhead to tail. The portable creel 20, 21 and 85 is placed in front of abackwinder head, and skinner yarn pieces wind onto one package or a fewpackages.

An advantage of this invention is that it provides a compact creel thatsubstantially reduces wasted yarn while making a comparable sizedcarpet.

Yet another advantage of this invention is that it provides for improvedquality by reducing yarn slack ends.

Still another advantage of this invention is that it improves plantthrough-put time because the warping process is eliminated for smallerjobs.

Another advantage of this invention is that it increases output becauseit provides for placing yarns of different thickness having differentlengths on yarn packages directly next to each other on the compactcreel. This also increases carpet design flexibility.

Some other advantages of the compressed, portable, tufting creelinclude:

Tufting setup time reduction

Carpet overrun overage reduction and control

Usable plant floor space increases

Yarn warehouse inventory reduction

Improved skinner yarn reclamation

Simplified scheduling of plant personnel

Material handling labor reduction

Redirection of non-value added labor to value added labor

Enhanced sample production

While certain embodiments of this invention have been described above,these descriptions are given for purposes of illustration andexplanation. Variations, changes, modifications and departures from thesystems and methods disclosed above may be adopted without departurefrom the scope or spirit of this invention.

What is claimed is:
 1. A compact creel comprising: a) a frame; b) holders affixed to the frame for holding yarn packages; and c) a header attachable on the frame for directing yarn from the yarn packages to a tufting machine, wherein the header comprises alignment means for aligning at least some of the yarn with the tufting machine and wherein the alignment means comprises at least one plate having a plurality of holes.
 2. The compact creel of claim 1, wherein each holder comprises a hollow tube affixed to the frame.
 3. The compact creel of claim 2, wherein the holder further comprises a retainer spring clip connected to the tube for holding the yarn packages.
 4. The compact creel of claim 1, further comprising, for each holder, one flexible tube having two ends for guiding yarn from the holder to the header.
 5. The compact creel of claim 4, wherein the flexible tube is positioned at least partially within the holder and further comprises an eyelet formed by heat flaring one of the ends of the flexible tube.
 6. The compact creel of claim 5, wherein the other end of the flexible tube is heat flared.
 7. The compact creel of claim 1, further comprising casters wheels on which the frame rests to enable it to be moved easily.
 8. The compact creel of claim 7, further comprising a yarn guide for guiding yarn from the frame over at least one other frame into the tufting machine.
 9. A compact creel comprising: a) a frame; b) holders affixed to the frame for holding yarn packages; and c) a header attachable to the frame for directing yarn from the yarn packages to a tufting machine, wherein the header comprises a first plate having a plurality of holes and a second plate having a plurality of holes that mate with the plurality of holes in the first plate, the second plate removably attached to the first plate.
 10. The compact creel of claim 9, further comprising a flexible tube having two ends, one of which ends is secured to the header.
 11. The compact creel of claim 10, wherein holders are affixed to both a front portion and a rear portion of the frame.
 12. The compact creel of claim 11, further comprising a vertical passageway for receiving the flexible tube between the front portion and the rear portion of the frame.
 13. The compact creel of claim 10, wherein the end secured to the header is disposed between the first and second plate of the header.
 14. A compact creel comprising: a) a first frame; b) holders affixed to the first frame for holding yarn packages; c) a header attachable to the first frame for directing yarn from the yarn packages to a tufting machine; d) casters wheels on which the first frame rests to enable it to be moved easily; and e) a second frame; and f) a yarn guide for guiding yarn from the second frame over the first frame into the tufting machine, wherein both the first frame and the second frame each further comprises an overlay upright having a ring affixed to the overlay upright and a line threaded through the ring for preventing yarn from an upper yarn package from falling onto a holder holding a lower yarn package causing an entanglement of yarn.
 15. The compact creel of claim 14, wherein the line comprises a monofilament line.
 16. A compact creel, comprising: a) a frame having a front and a back; b) a plurality of tubes affixed to the frame so that one yarn package may be held on each tube; c) a header comprising alignment means for aligning yarn from the yarn packages with a tufting machine, wherein the alignment means comprises at least one plate having a plurality of holes; and d) a length of flexible tubing having two ends for guiding yarn from a yarn package to the header.
 17. The compact creel of claim 16, wherein one end of the length of tubing is held within one of the tubes and the other end is attached to the header.
 18. The compact creel of claim 16, wherein both ends of the length of tubing are heat flared.
 19. The compact creel of claim 16, wherein some of the tubes are affixed to the front of the frame, some of the tubes are affixed to the back of the frame and the flexible tubing passes through a passageway between the front and back of the frame.
 20. A compact creel comprising: a) a frame having a front and a back; b) a plurality of tubes affixed to the frame so that one yarn package may be held on each tube; c) a header; d) a length of flexible tubing having two ends for guiding yarn from a yarn package to the header; and e) horizontal lines for preventing yarn from an upper yarn package from becoming entangled with another yarn package.
 21. The compact creel of claim 20, wherein at least one of the horizontal lines comprises a monofilament.
 22. A method for providing yarn to a tufting machine utilizing a compact creel, comprising: providing a compact creel having a frame with a holder and a header attached to the frame, wherein a flexible tube is positioned between the holder and the header; placing a yarn package containing yarn wound thereon onto the holder; blowing air through the holder, thereby forcing an end of the yarn through the holder and the flexible tube and through the header, wherein the yarn exits the header; and pulling the yarn exiting from the header and connecting the yarn to yarn pieces coupled to the tufting machine.
 23. A compact creel for yarn packages having a hollow core, the creel comprising: a plurality of support tubes in a vertical array; a plurality of lengths of flexible tubing positioned with one end of at least one length of flexible tubing within one support tube and the other end of the at least one length of flexible tubing positioned to direct yarn toward a tufting machine; and alignment means mountable on the creel for aligning yarn with the tufting machine.
 24. A compact creel comprising; a) a frame; b) holders affixed to the frame for holding yarn packages; and c) a header having a length and mountable on the frame for directing yarn from the yarn packages to a tufting machine, wherein the header comprises a plurality of organized positions along its length, each position capable of receiving yarn from a pre-determined yarn package and organizing the yarn relative to the tufting machine. 